US5934415A - Brake actuator service limit sensor - Google Patents
Brake actuator service limit sensor Download PDFInfo
- Publication number
- US5934415A US5934415A US08/863,655 US86365597A US5934415A US 5934415 A US5934415 A US 5934415A US 86365597 A US86365597 A US 86365597A US 5934415 A US5934415 A US 5934415A
- Authority
- US
- United States
- Prior art keywords
- spring member
- section
- actuator
- brake
- actuator rod
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D66/00—Arrangements for monitoring working conditions, e.g. wear, temperature
- F16D66/02—Apparatus for indicating wear
- F16D66/021—Apparatus for indicating wear using electrical detection or indication means
- F16D66/022—Apparatus for indicating wear using electrical detection or indication means indicating that a lining is worn to minimum allowable thickness
- F16D66/025—Apparatus for indicating wear using electrical detection or indication means indicating that a lining is worn to minimum allowable thickness sensing the position of parts of the brake system other than the braking members, e.g. limit switches mounted on master cylinders
Definitions
- the present invention relates to a system to measure the condition of a vehicle brake and, more specifically, to a system to detect and generate an electrical signal when the brake actuator travel exceeds a predetermined limit thereby indicating the need for brake service.
- a common type of air brake system for trucks utilizes an actuator associated with each brake.
- the actuator has an opening in one side through which an actuator rod extends, the actuator rod being in turn connected to the actual vehicle brake through a suitable mechanical linkage such as an automatic slack adjuster which is well known in the art.
- a spring or the like within the actuator holds the push rod in a relatively retracted position when the brake is off.
- pressurized air is supplied to the actuator and the pressurized air causes the actuator rod to move along its longitudinal axis, in a direction out of the actuator. This movement continues until the brake engages and provides a return force that balances the force provided by the air pressure.
- the first of these solutions is a device known as a slack adjuster that is included in the linkage between the actuator rod and the brake.
- a slack adjuster removes slack from this linkage, thereby reducing the amount of actuator rod travel necessary before the brakes are applied.
- Both automatic and manual slack adjusters are well known and in use.
- the slack removal operation is automatic, and occurs whenever a predetermined degree of slack develops in the linkage.
- an automatic slack adjuster is a relatively expensive and complex device, and is subject to occasional malfunction.
- a manual slack adjuster must be adjusted manually whenever excessive actuator rod travel develops in the brake system.
- an operator has no means of readily determining when such wear exists.
- U.S. Pat. No. 4,279,214 describes a brake wear indicator that comprises a sleeve that extends around the actuator rod and through the opening in the actuator through which the actuator rod extends. A relatively loose fit is provided between the indicator and the actuator rod, and a comparatively snug fit is provided between the indicator and the actuator. When the brakes are applied, the indicator is forced out of the actuator along with the actuator rod. When the brakes are subsequently released, the fit between the indicator and the actuator prevents the indicator from retracting.
- the brake wear indicator disclosed in this patent suffers from the problem that there is considerable variation in the size of the opening in the side of the actuator through which the actuator rod extends.
- indicators of various outside diameters must be provided in order to cover the different brands and models of actuators currently in use.
- no electronic signal is generated that can be used to alert the operation or the need for service without a visual inspection of each brake assembly.
- One of the simplest kind of devices is a split ring plastic sleeve designed to slip over the air pressure chamber actuator rod, and thereafter provide a visual indication of actuator rod travel distance or stroke extension. Excessive actuator rod travel indicates a level of brake lining wear that warrants replacement of the linings.
- Another device which likewise acts as a visual indicator involves modification to the actuator rod itself. A colored band is painted into a groove circumferentially machined in the actuator rod.
- U.S. Pat. No. 3,298,466 discloses a brake wear indicator that comprises an extension of the return spring of the actuating cylinder that extends from the interior of the actuating cylinder to the exterior where it is visible for inspection. When the brakes are applied, the return spring is compressed and the extension projects from the actuating cylinder. The greater the distance the extension projects the greater the wear of the brake linings.
- Prior art slack adjusters have used switching devices to signal when the brake adjuster has reached the end of its available travel thereby signaling the need for brake service. Examples of such devices are disclosed in U.S. Pat. Nos. 3,776,329; 5,253,735; 5,285,190; 5,339,069 and 5,358,075 the disclosures of which are hereby incorporated by reference.
- the switch which is mounted to the slack adjuster, is electrically connected to a monitoring device using two connecting wires. These types of devices function to electrically signal when the brake slack adjuster has traveled to its service limit thereby notifying the operator of the need for brake service.
- Another method of signaling when brake service is required is a system to monitor the travel of the pushrod of the brake actuator.
- One such device is described in U.S. Pat. No. 4,757,300 to Sebalos, the disclosure of which is hereby incorporated by reference.
- Sebalos a magnet is secured to the actuator rod of a brake actuator which magnetically activates a switch mounted to the housing of the brake actuator when the rod travels to its service limit.
- the switch is connected to an electronic circuit to alert the operator of the need for brake service.
- U.S. Pat. No. 5,450,930 uses a sensor mounted inside the actuator housing where the sensor is activated by a structure attached to the actuation rod.
- the sensor can be a magnetic structure, a contacting switch(es) or a load cell.
- the present invention provides an apparatus for electronically signaling when excessive brake wear has occurred in a brake of the type which uses a moveable actuator rod to displace an actuator linkage to activate the brake.
- a switch is mounted to the actuator housing so as to engage a specific increased diameter section of the actuator rod when the travel of the rod approaches or exceeds a predetermined service limit although the switch can be of the type known in the art as "normally closed” or conversely of the type known as “normally open” depending on the nature of the signal to be provided to the monitor electronics.
- the switch is normally closed by action of a spring member which encircles the actuator rod although the switch is activated by the action of the spring which holds the switch in an activated position when the actuator travel is within prescribed operational limits.
- the spring contacts a larger diameter section of the rod, the spring is moved to open the switch to signal when the actuator rod has reached a service limit position and the brakes need replacement or further adjustment.
- the switch assembly is mounted to a first end of the spring member and has contacts which extend to electrically contact a second end of the spring member when the spring member is encircling the smaller diameter section of the actuator rod.
- the switch contacts can be environmentally sealed using a rubber boot member. As the spring member encounters the larger diameter section of the actuator rod, the contacts are pulled away from the second end of the spring member thereby electrically opening a circuit.
- the switch contacts are mounted in a switch assembly on the first side of the spring member and the spring assembly is mounted to the actuator housing to encircle the actuator rod.
- One provision of the present invention is to provide a switching device to electrically indicate when a brake actuator has reached a predetermined travel limit.
- Another provision of the present invention is to provide a switching device mounted to the outside of the actuator housing to electrically indicate when a brake actuator has reached a predetermined travel limit.
- Another provision of the present invention is to provide a switching device actuated by a change in the diameter of the actuator rod of a brake actuator when the brake actuator has reached a predetermined travel limit.
- Another provision of the present invention is to provide a switching device mounted to a first end of a spring member having electrical contacts which extend to make electrical contact with a second end of the spring member when a brake actuator is within its travel limits.
- Another provision of the present invention is to provide a spring member mounted to the outside of a brake actuator housing which encircles the actuator rod where the spring member is forced apart by a larger diameter section of the actuator rod when a predetermined travel limit position is reached.
- Still another provision of the present invention is to provide an environmentally sealed switching device mounted to the first end of a spring member where the spring member is activated by contacting a larger diameter section of an actuator rod.
- FIG. 1 is a cross-sectional view of the actuator rod, spring member and switch device of the present invention in a normal position
- FIG. 2 is a cross-sectional view of the actuator rod, spring member and switch device of the present invention in a service position;
- FIG. 3 is a perspective view of the spring member and switch assembly of the present invention.
- FIG. 4 is a side elevational view of the present invention mounted to a brake actuator housing
- FIG. 5 is a partial perspective view of the present invention mounted to a brake actuator housing
- FIG. 6 is an elevational view of the mounting bracket of the present invention.
- FIG. 7 is a cross-sectional view of a first alternate embodiment of the present invention.
- FIG. 8 is a cross-sectional view of a second alternate embodiment of the present invention.
- FIG. 1 a cross-sectional view of the travel limit sensor 2 of the present invention in a normal position is shown.
- the spring member 4 is made of a flexible material and has a first section 6A and a second section 6B where the spring member 4 encircles the actuator rod 8 of a brake actuator.
- the spring member 4 is comprised of a rod section 4A and a spring section 4B which is attached to the major section 4A and provides a spring force thereto.
- the actuator rod 8 has a large diameter section 10 joined to a small diameter section 12 and axially extends out of the brake activator housing 29 (see FIG. 4) passing through the rod section 4A of the spring member 4.
- the large diameter section 10 preferably has a simple increase in diametrical cross-section as compared to the small diameter section 12 but could consist of only a section of the actuator rod 8 having an increased cross-sectional dimension.
- a switch assembly 14 is mounted to the first section 6A of the spring member 4 and has electrical contacts 16A and 16B which extend from switch assembly 14 to make electrical contact with a conduction plate 17 which electrically connects 16A to 16B when the spring member 4 is in its normal state thereby closing the switch assembly 14.
- the conduction plate 17 is attached to a plate housing 15 which is molded from a flexible electrical insulating material into an opening formed in the second section 6B of the spring member 4.
- the plate housing 15 extends to form a dust boot 18.
- a contact housing 22 mounts to the first section 6A of the spring member 4 and holds the electrical contacts 16A and 16B in position.
- the contact housing 22 is molded from an electrical insulation material and is molded into an opening formed in the first section 6A of the spring member 4.
- the dust boot 18 extends from the conduction plate housing 15 to the contact housing to cover the contacts 16A and 16B for environmental protection.
- the rod section 4A of the spring member 4 surrounds the larger diameter portion 10 of the actuator rod 8 when the actuator rod 8 has reached and/or exceeded a predetermined travel limit.
- the spring section 4B provides a contraction force to the spring member 4 to maintain contact between the conduction plate 17 and the electrical contacts 16A and 16B when the spring member 4 is not in contact with the large diameter section 10 of the actuator rod 8.
- the switch assembly 14 is electrically connected to an electronics module 24 by wire connector 20A and to a brake shoe wear sensor 23 by connector 20B.
- the switch assembly 14 would be normally open with the rod section 4A contacting the large diameter section 10 and then close when the small diameter section 12 enters the rod section 4A.
- FIG. 2 of the drawings a cross-sectional view of the actuator rod 8, spring member 4 and switch device 14 of the present invention showing the travel limit sensor 2 and the actuator rod 8 in a service limit position.
- the actuator rod 8 passes through the spring member 4 without contact between the two elements, as long as the brake actuator 28 is within its normal operating range (see FIG. 1).
- the actuator rod 8 passes through the travel limit sensor 2 in its large diameter section 10 and the rod section 4A contacts the actuator rod 8 at its large diameter section 10, first and second electrical contacts 16A and 16B are forced away from the conduction plate 17 and the electrical circuit is opened between the wire connections 20A and 20B to the wear sensor 23 and to the electronics module 24.
- the actuator rod 8 has moved out of the actuator housing 29 to the extent that the large diameter section 10 passes through the spring member 4 contacting and expanding the spring member 4 causing the first and second electrical contacts 16A and 16B to be pulled away from the conduction plate 17 which is attached to the second section 6B of the spring member 4.
- FIG. 3 is a perspective view of the spring member 4 and switch assembly 14 of the present invention.
- the plate housing 15 is attached or molded onto the second section 6B of the spring member 4 while the contact housing 22 is attached or molded onto the first section 6A of the spring member 4.
- the rod section 4A partially encircles the actuator rod 8 while the function of the spring section 4B is to provide a restoring spring force to the spring member 4 tending to close the switch assembly 14.
- FIG. 4 of the drawings a side elevational view of the present invention mounted to a brake actuator assembly 28 is shown.
- the actuator rod 8 axially extends from the actuator housing 29 and a rod clevis 30 is attached to the end of the actuator rod 8 for attachment to a slack adjuster (not shown) or another type of brake actuator linkage.
- Mounting bracket 32 is in some manner attached to the axle of the vehicle and supports the brake actuator 28 and a rotating shaft (not shown) which passes through shaft opening 34 to the brake and, for example, is connected at one end to the slack adjuster and at a second end to an S-cam.
- a switch bracket 36 is mounted between the mounting bracket 32 and the actuator housing 29 to position the travel limit sensor 2.
- a switch bracket 32 allows the travel limit sensor 2 to move slightly relative to the actuator rod 8 to allow for tolerancing and free-play in the actuator rod 8 relative to the actuator housing 29.
- the switch bracket 32 is trapped between the actuator housing 29 and the mounting bracket 32.
- the rod clevis 30 is shown attached to the end of actuator rod 8 where the actuator rod 8 extends through the spring member 4 and has a large diameter section 10 and a small diameter section 12 where the small diameter section 12 passes through the spring member 4 without contacting the major section 4A.
- the large diameter section 10 is not visible since it is located inside of the actuator housing 29 under normal conditions until the service limit of travel is reached when the large diameter section 10 enters the spring member 4.
- FIG. 5 is a partial perspective view of the present invention mounted to a brake actuator housing 29.
- the travel limit sensor 2 is trapped between the actuator housing 29 and the switch bracket 32 and is allowed to move slightly relative to the actuator housing 29 to accommodate misalignment and movement of the actuator rod 8.
- FIG. 6 an elevational view of the switch bracket 36 of the present invention is shown.
- Two bolt openings 39A and 39B allow for mounting to the actuator housing 29.
- the retainer section 40 is offset to capture the travel limit sensor 2 but allow for its movement relative to the actuator housing 29.
- Two connector supports 38A and 38B are used to restrain the electrical wire connectors 20A and 20B.
- a large rod opening 42 provides clearance for passage of the actuator rod 8 through the switch bracket 36.
- FIG. 7 a cross-sectional view of a first alternate embodiment of the travel limit sensor 2' of the present invention is shown.
- the spring member 4' operates in the same manner as is previously disclosed, however, the switch assembly 14' has been modified so that the first and second electrical contacts 16A and 16B do not contact the conduction plate 17 until the large diameter section 10 of the actuator rod 8 passes through the spring member 4' at rod section 4A' forcing the spring member 4' open.
- Spring section 4B' functions to hold the first and second contacts 16A and 16B away from the conduction plate 17.
- the switch assembly 14' is mounted to a first section 6A' of the spring member 4' with an opposite orientation from that previously disclosed such that the first and second contacts 16A and 16B face toward the conduction plate 17 now mounted to a second end extension 44 which is slotted to pass over the first section 6A' (or vice versa).
- the switch assembly 14' is now normally open and closes when the rod section 10 contacts the large diameter section of the spring member 4'.
- the electronics module must be reprogrammed to accommodate the opposite switch action with a normal state being open and an abnormal state being closed.
- FIG. 8 is a cross-sectional view of a second alternate embodiment of the travel limit sensor 2" of the present invention where the spring member 4" has been modified to permit the switch assembly 14 to be mounted between the rod section 4A" and the spring section 4B".
- the first and second electrical contacts are pulled away from the conduction plate 17 thereby operating in a manner similar to the embodiment disclosed with reference to FIG. 1.
Abstract
Description
Claims (8)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/863,655 US5934415A (en) | 1997-05-27 | 1997-05-27 | Brake actuator service limit sensor |
CA002238543A CA2238543C (en) | 1997-05-27 | 1998-05-25 | Brake actuator service limit sensor |
AU69033/98A AU731450B2 (en) | 1997-05-27 | 1998-05-27 | Brake actuator service limit sensor |
ARP980102468A AR012874A1 (en) | 1997-05-27 | 1998-05-27 | A DEVICE TO DETECT AND INDICATE ELECTRICALLY A WEAR OF THE BRAKE OF A VEHICLE. |
GB9811393A GB2327726B (en) | 1997-05-27 | 1998-05-27 | Brake actuator service limit sensor |
BR9804998-4A BR9804998A (en) | 1997-05-27 | 1998-05-27 | Brake actuator limit sensor for maintenance purposes |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/863,655 US5934415A (en) | 1997-05-27 | 1997-05-27 | Brake actuator service limit sensor |
Publications (1)
Publication Number | Publication Date |
---|---|
US5934415A true US5934415A (en) | 1999-08-10 |
Family
ID=25341511
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/863,655 Expired - Fee Related US5934415A (en) | 1997-05-27 | 1997-05-27 | Brake actuator service limit sensor |
Country Status (6)
Country | Link |
---|---|
US (1) | US5934415A (en) |
AR (1) | AR012874A1 (en) |
AU (1) | AU731450B2 (en) |
BR (1) | BR9804998A (en) |
CA (1) | CA2238543C (en) |
GB (1) | GB2327726B (en) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6072389A (en) * | 1999-09-20 | 2000-06-06 | Strasburger; Bill | Brake adjustment monitor device for automotive vehicles |
US6345699B1 (en) * | 1999-12-23 | 2002-02-12 | Dana Corporation | Brake actuator service limit sensor |
US20020195298A1 (en) * | 2001-02-08 | 2002-12-26 | Volvo Trucks North America, Inc. | Vehicle diagnostic system |
US6581728B2 (en) | 2001-02-08 | 2003-06-24 | Volvo Trucks North America, Inc. | Brake shoe proximity sensor |
US6615639B1 (en) | 1992-02-25 | 2003-09-09 | Ralph Heinzen | Self monitoring static seal |
US20040075218A1 (en) * | 1998-06-03 | 2004-04-22 | Ralph Heinzen | Self monitoring static seal with optical sensor |
US20040251090A1 (en) * | 2003-06-16 | 2004-12-16 | Morris Royston Leonard | Brake pad clearance sensor |
US20070131491A1 (en) * | 2005-12-13 | 2007-06-14 | Arvinmeritor Technology, Llc | Brake lining wear sensor between lining blocks |
US20090229926A1 (en) * | 2008-03-11 | 2009-09-17 | Craig Schaefer | Proximity sensor for brake wear detection |
US9482301B2 (en) | 2015-03-25 | 2016-11-01 | Honeywell International Inc. | Brake disc stack wear measurement |
CN109826888A (en) * | 2019-03-28 | 2019-05-31 | 山西峰润众盛汽车配件制造有限公司 | A kind of self-regulated arm increases the device of warning function |
US10471947B1 (en) | 2018-04-27 | 2019-11-12 | Honeywell International Inc. | Determining estimated remaining use of brake assembly by transceiver |
US10941826B2 (en) | 2018-09-12 | 2021-03-09 | Honeywell International Inc. | Determining estimated remaining use of brake assembly |
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US2146357A (en) * | 1936-07-09 | 1939-02-07 | Otto W Schweikle | Brake condition indicator |
US3145275A (en) * | 1962-03-30 | 1964-08-18 | Rehrig Pacific Co | Electrical switch and actuator apparatus |
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1997
- 1997-05-27 US US08/863,655 patent/US5934415A/en not_active Expired - Fee Related
-
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- 1998-05-25 CA CA002238543A patent/CA2238543C/en not_active Expired - Fee Related
- 1998-05-27 BR BR9804998-4A patent/BR9804998A/en not_active IP Right Cessation
- 1998-05-27 AR ARP980102468A patent/AR012874A1/en unknown
- 1998-05-27 GB GB9811393A patent/GB2327726B/en not_active Expired - Fee Related
- 1998-05-27 AU AU69033/98A patent/AU731450B2/en not_active Ceased
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US3145275A (en) * | 1962-03-30 | 1964-08-18 | Rehrig Pacific Co | Electrical switch and actuator apparatus |
US3298466A (en) * | 1965-02-03 | 1967-01-17 | Kelsey Hayes Co | Brake wear indicator |
US3776329A (en) * | 1971-03-19 | 1973-12-04 | Self Energizing Disc Brakes Lt | Brake wear and adjustment device |
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US5450930A (en) * | 1993-12-09 | 1995-09-19 | Mgm Brakes | Heavy duty electronic brake stroke indicator |
US5477945A (en) * | 1994-04-14 | 1995-12-26 | Bpw Bergische Achsen Kommanditgesellschaft | Drum brake arrangement for vehicle axles |
US5441128A (en) * | 1994-07-22 | 1995-08-15 | Hoyt; Gordon C. | Reference bracket means for brake stroke length adjustment gauge |
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US6072389A (en) * | 1999-09-20 | 2000-06-06 | Strasburger; Bill | Brake adjustment monitor device for automotive vehicles |
US6345699B1 (en) * | 1999-12-23 | 2002-02-12 | Dana Corporation | Brake actuator service limit sensor |
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US20020195298A1 (en) * | 2001-02-08 | 2002-12-26 | Volvo Trucks North America, Inc. | Vehicle diagnostic system |
US6581728B2 (en) | 2001-02-08 | 2003-06-24 | Volvo Trucks North America, Inc. | Brake shoe proximity sensor |
US6680672B2 (en) | 2001-02-08 | 2004-01-20 | Volvo Trucks North America, Inc. | Vehicle diagnostic system |
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US20090229926A1 (en) * | 2008-03-11 | 2009-09-17 | Craig Schaefer | Proximity sensor for brake wear detection |
US9441692B2 (en) * | 2008-03-11 | 2016-09-13 | Honeywell International Inc. | Proximity sensor for brake wear detection |
US9482301B2 (en) | 2015-03-25 | 2016-11-01 | Honeywell International Inc. | Brake disc stack wear measurement |
US10471947B1 (en) | 2018-04-27 | 2019-11-12 | Honeywell International Inc. | Determining estimated remaining use of brake assembly by transceiver |
US10941826B2 (en) | 2018-09-12 | 2021-03-09 | Honeywell International Inc. | Determining estimated remaining use of brake assembly |
CN109826888A (en) * | 2019-03-28 | 2019-05-31 | 山西峰润众盛汽车配件制造有限公司 | A kind of self-regulated arm increases the device of warning function |
Also Published As
Publication number | Publication date |
---|---|
AR012874A1 (en) | 2000-11-22 |
AU731450B2 (en) | 2001-03-29 |
CA2238543A1 (en) | 1998-11-27 |
GB2327726A (en) | 1999-02-03 |
AU6903398A (en) | 1998-12-03 |
GB9811393D0 (en) | 1998-07-22 |
CA2238543C (en) | 2006-08-15 |
BR9804998A (en) | 2000-11-28 |
GB2327726B (en) | 2001-01-10 |
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